GEAFOL Cast-Resin Transformers

Operating Instructions

Answers for energy.

 Contents
Range covered 3 Temperature monitoring 9
General 9
Application 3 Description 9
Version with PTC 9
Description 4 Version with PT 100 9
Core 4 Evaluation devices 9
Windings 4
Insulation 4 Commissioning 10
Supports 4
Recommendations for
Installation 5 cleaning and inspection 11
Unloading, handling, unpacking, Cleaning transformers 11
inspection, cleaning and storage 5 Cleaning method 11
Setting up 5 Checking the torque values of bolted
Housings 6 connections 11
Minimum clearances 6 Checking warning facilities 11
Checking fitted fans 11
Connecting 7 Protective housings 11
Surface preparation 7 Faults 11
Fastenings 7
Contact pressure 8
Earthing 8

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 Low-voltage Upper clamping
terminal

Lifting lugs
Connection for temperature
monitoring system
Lashing lugs

Cast high-voltage winding

High-voltage terminal

Delta connection
High-voltage
tappings
(these may also
be on the
low-voltage
terminal side)
Earthing terminal
Pulling lugs
Lower clamping

Wheels, can be turned through 90°

Fig. 1: 630 kVA GEAFOL cast-resin transformer 10 ± 2 x 2.5 %/0.4 kV low-voltage connection side

Range covered Application

These operating instructions are applicable
to all GEAFOL® cast-resin transformers of
three-phase and single-phase design,
including special versions such as rectifier
and star-point transformers.
GEAFOL cast-resin transformers are par-
ticularly suitable for applications where
fire or ground-water regulations would
involve additional expense if liquid-im-
mersed transformers were used, e.g. in
ships, offshore and wind power plants,
department stores, underground railways,
sports stadiums and meeting halls, pump-
ing stations and water catchment areas.
They are also being used more frequently
in industrial applications for load center
substations and supply feeder stations
because, with cast-resin transformers,
there are no civil works costs for oil catch
pits and fire protection. This also greatly
facilitates relocation of the transformers
should it be necessary.

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 Description
Core Insulation
Only grain-oriented, cold-rolled plates The insulation structure is dimensioned
insulated on both sides are used for the on the basis of the impulse voltage distri-
iron core. bution. It ensures freedom from partial
discharge up to twice the rated voltage,
The leg and yoke cross-sections are as well as thermal and mechanical
staggered by different lamination widths. strength.
The outer legs have miter joints and the
middle leg a double miter joint at the Supports
yoke junction. A clamping arrangement designed specifi-
cally for the characteristics of the strip
Windings windings and flexible bracing of the coils
The high-voltage winding is made of alu- ensure both high short-circuit strength
minum strips and high-quality insulating and also a very low noise level.
film. Each phase winding is formed from
several separate coils connected in series
which are encapsulated in resin under a
vacuum. The winding ends and tappings
are routed to threaded bushes and are
encapsulated with the remainder of the
winding. The low-voltage winding is
made of aluminum strips and cast-resin
impregnated insulating film (prepreg).

4 |
 max. 45°
max. 45°
Fig. 2: Lifting of the transformer
Installation
Unloading, handling, unpacking,
inspection, cleaning and storage
GEAFOL transformers may only be un-
loaded and transported by means of the
lifting lugs provided on the upper con-
structional cross beam (see Fig. 1). In
general four individual cords have to be
used. The information about pulling at
an angle provided on the labels on the
lifting lugs must be observed (see Fig. 2).
If a transformer is moved on its rollers,
the points of action are the pulling lugs
provided in the lower cross beams (see
Fig. 1) or on the truck.
Do not push or pull on the high-voltage
windings or their connecting tubes.
GEAFOL cast-resin transformers may only
be transported by fork-lift truck if the
transporting party ensures that
■ the transformer is adequately secured
against the risk of tipping and/or falling
and
■ damage to the iron core between the
cross beams and any attached accesso-
ries such as fans or make-proof earthing
switches is reliably prevented.
If signs prohibiting transport by fork-lift
are attached near the bottom of the trans-
former, transport of the transformer by
fork-lift is absolutely prohibited!
GEAFOL transformers should be unpacked
in a covered area and inspected immedi-
ately for transportation damage. Any
damage visible on delivery must be noted
in the transport papers and confirmed by
the supplier. The sender must be informed
immediately so that a suitable loss adjust-
ment procedure can be initiated, if neces-
sary with the participation of the transport
insurance company.
If necessary, the transformer must be
cleaned before commissioning (see recom-
mendations for cleaning and checking
GEAFOL cast-resin transformers on
Page 11).
If the transformer is not commissioned
straight away, it must be stored in a roofed
room that is dry and protected from sun-
light. The room’s temperature must not
drop below –25 °C (unless otherwise
agreed). It is not recommended to cover
it with plastic film, owing to the risk of
condensation.
The transformer must be packed in a
protective foil when being transported
on-site or being stored. This effectively
prevents the ingress of dust and foreign
matter. In order to prevent condensation
forming, an adequate quantity of desiccant
agent (such as Silicagel) must be enclosed
in the packaging.
Setting up
GEAFOL cast-resin transformers should
only be installed in a roofed room or cell
that is dry and protected from sunlight,
where the degree of protection assured is
at least IP 23. If appropriately coated with
special paint and if an outdoor housing is
used they are also suitable for installation
outdoors. GEAFOL cast-resin transformers
need an adequate supply of fresh air to
dissipate the heat losses. Approx. 200 m3
of fresh air per hour and for each kW of
heat loss is the recommended value;
further information can be found in the
GEAFOL planning notes).
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 c c

b a b a

Fig. 3: Minimum clearances around GEAFOL Fig. 4: Minimum clearances around GEAFOL
cast-resin transformers with switching strip (1) cast-resin transformers with contact tubes (2)

Also make sure that the clearances from
the surface of the cast-resin coils to the
walls, busbars, earthed parts, etc. satisfy
the applicable installation and safety
regulations (see Fig. 3 and 4).
Cast-resin transformers are not safe to
touch. The power must be shut off before
work is carried out on the transformer.
Applicable regulations must be observed.
Transformers are designed in accordance
with the applicable standards for the fol-
lowing cooling air values:
■ 40 °C maximum
■ 30 °C daily average
■ 20 °C annual average
If operated normally, the transformer
should attain its expected service life. In
particular, the average annual tempera-
ture and the load crucially influence the
service life.
GEAFOL cast-resin transformers for instal-
lation at high altitudes over 1,000 m above
mean sea level are identified on the rat-
ing plate with the maximum permissible
installation altitude. When installed ac-
cordingly the minimum clearances listed
in Table 1 must be increased by 1 % for
each 100 m above the altitude of 1,000 m.
Housings
When using housings, note that all bolted
connections must be firmly tightened
during installation, thus avoiding damage
to the transformer, e.g. as a result of nuts
falling out.
Minimum clearances
Adequate space must always be ensured
around the transformer to enable con-
nections to be made and also to keep to
the necessary electrical clearances. The
minimum distances to prevent flashover
are shown in Table 1 in conjunction with
the sketch in Fig. 3 or 4.

Maximum voltage for Rated lightning impulse Minimum clearances

equipment Um1) (rms value) withstand voltage ULI1)
List 1 List 2 a b c d
kV kV kV mm mm mm mm
12 – 75 120 * 50 40
24 95 – 160 * 80 50
24 – 125 220 * 100 70
36 145 – 270 * 120 90
36 – 170 320 * 160 110
1) See IEC 60071
* If there are high-voltage taps on this side, the value in column a applies to the clearance b; otherwise, the value in column c applies.
Table 1
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1 2
b 2
1 Bare tap
Fig. 5: Minimum clearance for cable connection;
see Table 1
Connecting
On the high-voltage side, the transformer
is connected to the the surfaces of the
connecting tubes or the terminals provided
on the strip (delta connection), or to the
cast-on post insulators of the high-voltage
pottings (Y connection). When connecting
by means of cables, make sure that they
feature adequate strain relief and are
routed so that the voltage clearances are
maintained in line with relevant regula-
tions. The minimum clearances for cable
connections must be observed as shown
in Table 1 and Fig. 5.
On the low-voltage end, the transformer
is connected to the aluminum bars pro-
vided for this purpose (in special cases,
to copper bars). The following guidelines
must be observed when connecting con-
ductor bars via expansion straps.
Methods of bolting Expansion
Example strap
Busbar
Transformer table
4 Busbar
1 Hexagon screw,
ISO 4014 or ISO 4017
3
2 Conical spring washer
DIN 6796
3 Hexagon nut, ISO 4032
4 Washer, DIN 7349 4
Fig. 6: Transformer connection with busbar
Surface preparation Fastenings
Before making any bolted or terminal Corrosion-proof parts must be used for
connection, it is necessary to remove the bolted connections. Preference should be
thin, invisible layer of oxide from the alu- given to bolts belonging to strength class
minum surface, which is a poor conductor 8.8 or 10.9. In order to transmit the bolt-
of electricity. ing force to the largest possible contact
surface, stiffened washers should be
For this purpose, the contact surfaces inserted under the bolt head and the nut.
must be polished bare metal. Every time Spring elements are also necessary to
a point of contact is opened, the alumi- accommodate heat-generated tension
num contact surface must be subjected resiliently, so as to compensate for plastic
to the whole preparation process again deformation and to thus maintain the
before it is screwed back together. If the required minimum contact pressure at all
transformer is installed indoors in a room times. Both conditions are met by conical
where condensation is frequently to be spring washers to DIN 6796, which are
expected or where corrosive gases are widely used particularly for conductor bar
present, an aluminum sheet copper-plated threaded fastenings.
on one side (known by the trade name
“Cupal”, for example,) must be inserted
between Cu-Al contact points so that the
aluminum side is in contact with the alu-
minum bar and the copper side is in con-
tact with the copper terminal. All edges
of this sheet must protrude some milli-
meters so as to ensure that any corrosion
occurring in the transition area remains
outside the contact zone. Corrosion can
be largely avoided by applying a protective
coating to the cut edges of this “Cupal”
sheet. Tinned terminals can be combined
with bare copper, aluminum or silver-
plated surfaces.
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Contact pressure
The bolts should be tightened with a
torque wrench. This ensures that the bolt
connections are made with adequate
contact pressure.
To eliminate any settling in the joints,
it is advisable to retighten the bolts after
a few hours. However, the torque then
applied should not be greater than the
torque applied during the first installation.
We recommend the tightening torque
values listed in Table 2 for tightening
the ungreased (dry) bolted joints.
Bolt Torque [Nm]
M6
M8
M10
M12
M16
Table 2: Tightening torque values for
the phase connections and tapping links
8 |
Expansion
strap
2 3
1 4
1
1 Washer, ISO 7089
2 Hexagon screw, ISO 4014 or ISO 4017
3 Hexagon nut, ISO 4032
4 Conical spring washer, DIN 6796
Fig. 7: Transformer connection with cable lug Fig. 8: GEAFOL cast-resin transformers
Low-voltage end connection
If the low-voltage connection is estab-
lished with busbars, an expansion strap
(flexible connection element) must be
installed between the transformer and
the busbars. This keeps mechanical
stresses away from the transformer
(see Fig. 8) and largely prevents trans-
mission of structure-borne transformer
noise. Detailed information on bolted
busbar connections can be found in
DIN 43673.
Earthing
Make sure that the necessary earthing
connection is established on accessories
installed on the transformer after installa-
tion. Transformer housings must also be
dry
earthed in accordance with the known
10 earthing specifications.
20
40
75
140
Temperature monitoring
General
The measuring sensors of the temperature
monitoring system record the winding
temperature. This acts as overload protec-
tion against excessive heat generation in
the transformer winding. This protection
does not prevent increased rate of service
life consumption if the cooling air temper-
atures are not kept within specified limits
(see list, page 6). The following versions
or combinations can be installed:
Description
The temperature monitoring system for
GEAFOL cast resin transformers consists of
PTC thermistor, DIN 44082-compliant tem-
perature sensors or platimum resistance
thermometers (PT100) in accordance
with IEC 60751 and the associated evalu-
ation devices. Positioning of the overload
protection is identical for both systems.
The evaluation devices must be designed
for processing the signals from the par-
ticular system.
Version with PTC Evaluation devices
At least one PTC thermistor is installed For the function and connection of the
in one of the low-voltage windings to be evaluation devices refer to the particular
monitored. This is provided for triggering. operating instructions. Information about
Further systems can be installed, likely- the devices can be found at
wise retrospectively, e.g. for warning www.ziehl.de and www.tecsystem.it
(coil temperature) and controlling fans.
The PTCs of the particular functional The setting values for the corresponding
stage are connected in series and are trigger device in the case of PT 100 tem-
routed to a terminal strip (max. 2.5 mm2) perature monitoring can be found on the
on the upper pressed metal sheet. information plate attached to the trans-
former.
Version with PT 100
At least one resistance thermometer
(PT 100) is installed in each of low voltage
winding to be monitored. The warning,
triggering or fan control functions must
be set on the evaluation device. The cor-
responding setting values can be found
on the information plate attached to the
transformer. By default the PT 100s are
routed in a three-conductor circuit to a
terminal strip (max. 2.5 mm2) on the upper
pressed metal sheet.
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 Commissioning
The transformer must have been cleaned Due to the low attenuation, it may take the
and it must not contain any foreign matter switch-on currents of GEAFOL cast-resin
(see also Installation, Page 5). transformers some time to decay. Refer
■ Check technical data on the rating to the test report for the exact values.
plate attached to the transformer This must be borne in mind when selecting
against the customer’s requirements. fuses and relay times.
■ Tighten all contact connections to the
torque stated in Table 2. If protection settings are wrong, the
■ Adjust any connecting brackets on the transformer will be switched off during
high-voltage tappings to the prevalent the power-on current surge. This will lead
voltage. to high excess voltages in the transformer
windings, where they may cause damage.
When large idling transformers are
switched on, in isolated cases visible
sparks may occur on the outside
(particularly in the area of the core
and the clamped parts), but these will
soon subside. This effect occurs for
reasons of physics and has no influence
on operating safety; it is not a defect.

10 |
 Faults
In case of faults that cannot be cleared
by the customer itself, a service department
of Siemens AG should be notified.

Phone: +49 (0) 7021/508-549

+49 (0) 7021/508-512
Fax: +49 (0) 7021/508-588
+49 (0) 7021/508-514
Mobile: +49 (0) 172/622 4291
+49 (0) 172/765 5074
E-mail: weber.guenther@siemens.com
daniel.tiefenthaeler@siemens.com

Recommendations for cleaning and inspection

GEAFOL cast-resin transformers are prac-
tically maintenance-free. If they are oper-
ated in very dusty installations, e.g. in
rolling mills, we recommend cleaning
several times a year.
In parallel, generally once every year,
the contact bolts, warning facilities and
functioning of any fitted fans should
be checked.
The transformer must be switched off on
all sides before maintenance work is be-
gun. All terminals must be shortcircuited
and earthed. The safety regulations must
be observed.
Cleaning transformers
Particular care must be paid to cleaning
all horizontal surfaces and support blocks
in the area between the low-voltage and
high-voltage coils where, according to ex-
perience, dirt can accumulate very easily.
Cleaning method
■ Rub the soiled surface with a cloth
soaked in a conventional tenside-based
cleaning agent. Then wipe over with a
dry cloth.
■ Use a vacuum cleaner to remove loose
parts and dirt in the cooling ducts as
far as they are accessible.
Checking the torque values
of bolted connections
The torque values of the transformers’
earthing terminals (and above all the
bolted connections of all electrical termi-
nals), the high-voltage tappings, and the
connections from one system to another
in the case of double-tier transformers
should be checked once every year. Use a
torque wrench or a force-limiting spanner
to check bolted connections against the
values listed in Table 2.
Checking warning facilities
The “Inspection” function for the evaluation
devices can be carried out as specified in
the operating instructions. Visual inspec-
tion of the terminal connections on the
transformer is recommended.
Checking fitted fans
If possible, the functioning and running
characteristics of fitted fans should be
checked once every year.
Please note:
On delivery, the default setting of the
monitoring system types T154 and
NT935 includes a functional test for fans.
If run in the factory standard setting,
every 96 hours the fans will undergo
a short test lasting 5 –10 minutes.
Protective housings
Protective housings can be cleaned in the
same way as control cabinets. Ensure par-
ticularly that air inlet and outlet openings
are clean of dust and dirt deposits.

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Published by and copyright © 2010:
Siemens AG
Energy Sector
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91058 Erlangen, Germany

Transformatorenwerk Kirchheim
Power Transmission Division
Transformers
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73230 Kirchheim/Teck, Germany
Phone: +49 (0) 7021 508-0
Fax: +49 (0) 7021 508-495

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Hungary
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For more information, please contact

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E-mail: support.energy@siemens.com

Power Transmission Division

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Printed in Germany
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Subject to change without prior notice.

The information in this document contains general
descriptions of the technical options available, which
may not apply in all cases. The required technical
options should therefore be specified in the contract.

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